Aircraft interior panel with acoustic materials

ABSTRACT

A panel assembly that includes a first panel having an inner surface and an outer surface, and a second panel having an inner surface and an outer surface. The second panel includes a plurality of rib members formed therein that extend inwardly. The rib members include an inner surface and an outer surface. A plurality of panel portions are defined between the plurality of rib members. The panel portions include an inner surface and an outer surface. The inner surface of the rib members are secured to the inner surface of the first panel, and the inner surface of the panel portions is spaced apart from the inner surface of the first panel to define at least first and second cavities.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/668,614 filed Jul. 6, 2012, which is incorporated herein by referencein its entirety.

FIELD OF THE INVENTION

The present invention relates to an aircraft interior panel, and, moreparticularly to an aircraft interior panel with noise attenuationproperties.

BACKGROUND OF THE INVENTION

Commercial aircraft, such as the Airbus A320 or Boeing 737 are typicallyconstructed from modular components, the size, weight and constructionof which are dictated by many considerations, including fuselagedimensions, aesthetic and safety considerations. Many of theserequirements are imposed by law or regulation. Aircraft components, suchas overhead stowage compartments, seats, lavatories, galleys, lightingsystems, etc. are all required to function within strictly confinedspaces.

Manufacturers of aircraft are constantly refining interior aircraftdesigns to achieve more comfort and utility for passengers and crewwithin carrier-imposed restraints on cost, weight, maintenancedown-time, and safety. The current interior wall panels used in theaircraft interior industry are based on a build up that has been aroundfor decades. The composite sandwich panel is a staple in the aircraftinteriors industry today. Many panel and acoustics providers are lookingfor new ways to evolve the composite sandwich panel by incorporatingdifferent treatments to the skin of the panel.

SUMMARY OF THE PREFERRED EMBODIMENTS

In accordance with a first aspect of the present invention there isprovided a panel assembly that includes a first panel having an innersurface and an outer surface, and a second panel having an inner surfaceand an outer surface. The second panel includes a plurality of ribmembers formed therein that extend inwardly. The rib members include aninner surface and an outer surface. A plurality of panel portions aredefined between the plurality of rib members. The panel portions includean inner surface and an outer surface. The inner surface of the ribmembers are secured to the inner surface of the first panel, and theinner surface of the panel portions is spaced apart from the innersurface of the first panel to define at least first and second cavities.In a preferred embodiment, the panel assembly includes a first acoustictreatment member positioned in the first cavity. The first acoustictreatment member is adhered to at least one of the inner surface of thefirst panel or the inner surface of the second panel. Preferably, aspace is defined between the first acoustic treatment member and one ofthe inner surface of the first panel or the inner surface of the secondpanel. In a preferred embodiment, the first acoustic treatment member iscomprised of at least first and second layers. Preferably, the firstacoustic treatment member is adhered to the inner surface of the secondpanel, and the second panel includes a plurality of raised portionsdefined therein. In a preferred embodiment, the panel assembly includesa second acoustic treatment member. The first acoustic treatment memberis adhered to the inner surface of the first panel and the secondacoustic treatment member is adhered to the inner surface of the outerpanel, and a space is defined between the first and second acoustictreatment members. In an embodiment, the second cavity defines a ductingspace and the does not include an acoustic treatment member therein. Ina preferred embodiment, the panel assembly includes an outer acoustictreatment member adhered to at least a portion of the outer surface ofthe second panel and a decorative panel adhered to the outer surface ofthe first panel member.

In accordance with a first aspect of the present invention there isprovided an aircraft fuselage wall that includes a plurality of framemembers and a panel assembly that includes a first panel having an innersurface and an outer surface, and a second panel having an inner surfaceand an outer surface. The second panel includes a plurality of ribmembers formed therein that extend inwardly and each define an outer ribcavity. The rib members include an inner surface and an outer surface. Aplurality of panel portions are defined between the plurality of ribmembers. The panel portions include an inner surface and an outersurface. The inner surface of the rib members are secured to the innersurface of the first panel, and the inner surfaces of the panel portionsare spaced apart from the inner surface of the first panel to define atleast first and second cavities. At least some of the frame members arereceived in at least some of the outer rib cavities.

In an exemplary embodiment, the present invention includes no fill andfare, e.g., bondo, (however, in another embodiment, fill and fare can beimplemented). In use, the present invention can provide an approximately8-10% reduction in noise transmission compared to the prior art(however, this range is only exemplary and is not a limitation).Furthermore, the production process is energy efficient and preferablyuses reusable and recyclable material. The panels provide zero to littlewater absorption, a favorable surface finish, approximately sixty secondpress time and overwrap decor with flam compliance. The panels can bemade of materials such as Ultem and glass fiber composite, thermoformedmaterial in a preferred embodiment. The panels can be crushed into alarge variety of shapes with integrated acoustic treatments.

In a preferred embodiment, the panel assembly includes two (inner andouter) panels bonded together. The inner panel has a smooth crosssection and the outer panel has a corrugated cross section. The outerpanel provides stiffness to the panel assembly with incorporatedstandoff ribs. It will be appreciated by those of skill in the art thatthe inner and outer panels can also be made of other materials such asphenolic (e.g., crush core honeycomb panels or layup laminates). Byspacing the two panels apart, the present invention provides a strongstructure that provides rigidity to the panel assembly. The doublepanel/wall construction, and the space/cavity therebetween, provides anacoustic barrier.

In a preferred embodiment, the cavity between the inner and outer panelincludes acoustic treatments, such as one or more layers of the same ordifferent materials that provide an acoustic barrier. In a preferredembodiment, the cavity includes a multiple layer treatment. The layersof the treatment are comprised of materials that have different acousticimpedances. Therefore, when noise is propagating therethrough, at eachinterface between different materials/layers, there is a reduction inthe efficiency of sound propagation producing a reduction in soundlevel. In an embodiment, another acoustic treatment can be positioned onthe outside of the corrugated outer panel for added acousticperformance.

As shown in the figures, in an exemplary embodiment, the presentinvention combines a decorative panel and a first structural panel withthe second structural panel to define a distance therebetween and theability to attach acoustic materials to the various structural surfaces.The ability to provide multiple material densities (including airpockets) in layers (key in noise attenuation) is increased with theassembly taught herein.

The invention, together with additional features and advantages thereof,may be best understood by reference to the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a panel assembly in accordance with anembodiment of the present invention;

FIG. 2 is an exploded perspective view of the panel assembly of FIG. 1;

FIG. 3 is a perspective view of an end of the panel assembly of FIG. 1;

FIG. 4 is a cross-sectional view of the panel assembly of FIG. 1;

FIG. 5 is a perspective view of the panel assembly of FIG. 1incorporated into the wall of an aircraft; and

FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description and drawings are illustrative and are not tobe construed as limiting. Numerous specific details are described toprovide a thorough understanding of the disclosure. However, in certaininstances, well-known or conventional details are not described in orderto avoid obscuring the description. References to one or an otherembodiment in the present disclosure can be, but not necessarily are,references to the same embodiment; and, such references mean at leastone of the embodiments.

Reference in this specification to “one embodiment” or “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiment is included in at least one embodimentof the disclosure. Appearances of the phrase “in one embodiment” invarious places in the specification do not necessarily refer to the sameembodiment, nor are separate or alternative embodiments mutuallyexclusive of other embodiments. Moreover, various features are describedwhich may be exhibited by some embodiments and not by others. Similarly,various requirements are described which may be requirements for someembodiments but not other embodiments.

The terms used in this specification generally have their ordinarymeanings in the art, within the context of the disclosure, and in thespecific context where each term is used. Certain terms that are used todescribe the disclosure are discussed below, or elsewhere in thespecification, to provide additional guidance to the practitionerregarding the description of the disclosure. For convenience, certainterms may be highlighted, for example using italics and/or quotationmarks: The use of highlighting has no influence on the scope and meaningof a term; the scope and meaning of a term is the same, in the samecontext, whether or not it is highlighted. It will be appreciated thatthe same thing can be said in more than one way.

Consequently, alternative language and synonyms may be used for any oneor more of the terms discussed herein. Nor is any special significanceto be placed upon whether or not a term is elaborated or discussedherein. Synonyms for certain terms are provided. A recital of one ormore synonyms does not exclude the use of other synonyms. The use ofexamples anywhere in this specification including examples of any termsdiscussed herein is illustrative only, and is not intended to furtherlimit the scope and meaning of the disclosure or of any exemplifiedterm. Likewise, the disclosure is not limited to various embodimentsgiven in this specification.

Without intent to further limit the scope of the disclosure, examples ofinstruments, apparatus, methods and their related results according tothe embodiments of the present disclosure are given below. Note thattitles or subtitles may be used in the examples for convenience of areader, which in no way should limit the scope of the disclosure. Unlessotherwise defined, all technical and scientific terms used herein havethe same meaning as commonly understood by one of ordinary skill in theart to which this disclosure pertains. In the case of conflict, thepresent document, including definitions, will control.

It will be appreciated that terms such as “front,” “back,” “top,”“bottom,” “side,” “short,” “long,” “up,” “down,” and “below” used hereinare merely for ease of description and refer to the orientation of thecomponents as shown in the figures. It should be understood that anyorientation of the components described herein is within the scope ofthe present invention.

Referring now to the drawings, wherein the showings are for purposes ofillustrating the present invention and not for purposes of limiting thesame, FIGS. 1-6 show a panel assembly 10 for use in the wall 100 of avehicle, such as an aircraft. In particular, the invention iscontemplated for use on commercial passenger aircraft. However, this isnot a limitation on the present invention and the panel assembly can beused elsewhere.

As shown in FIGS. 1-4, in a preferred embodiment, the panel assembly 10includes a first panel 12 having an inner surface 12 a and an outersurface 12 b and a second panel 14 having an inner surface 14 a and anouter surface 14 b. When positioned in an aircraft, the first panel isthe inner panel and the second panel is the outer panel. In a preferredembodiment, the second panel 14 is corrugated to form a plurality of ribmembers 16 and a plurality of panel portions 18. It will be appreciatedthat the inner and outer surfaces of the rib members and panel portionsare the same as the inner and outer surfaces of the outer panel.However, for ease of description, the rib members 16 include innersurface 16 a and outer surface 16 b and the panel portions 18 includeinner surface 18 a and outer surface 18 b.

Preferably, the second panel 14 includes a plurality of the rib members16 formed therein that extend inwardly and that each define an outer ribcavity 20. In a preferred embodiment, the inner surface 16 a of the ribmembers 16 are secured to the inner surface 12 a of the first panel 12.This can be accomplished by any method known in the art, such as gluing,adhering, affixing, securing with fasteners, welding, etc. Furthermore,an acoustic treatment member or layer or the like can be positionedbetween the inner surface 16 a of the rib members 16 and the innersurface 12 a of the first panel 12. This is within the scope of“securing” within the present invention.

As shown in FIG. 3, the inner surface of each panel portion 18 a isspaced apart from the inner surface of the first panel 12 a to define aplurality of cavities 22. In a preferred embodiment, at least a portionof the cavities 22 include acoustic treatment members 24 are positionedtherein. The acoustic treatment members 24 are comprised of materialsthat are known to reduce noise travel therethrough. For example, theacoustic treatment members 24 can be comprised of any combination (invarious layers) of the following materials types: Nomex felt or anotheracoustic felt, such as MC8-4596 from TexTech Industries; skin dampingmaterial, such as ADC-006 from EAR Specialty Composites, K1050 orFRO54OU from Damping Technologies, Inc.; rubber or vinyl acousticsheets, such as Isodamp C-1002 from EAR Specialty Composites. None ofthese materials are limiting and the acoustic treatment members can bemade of any material with acoustic damping properties known in the art.

In a preferred embodiment, the acoustic treatment members 24 include anumber of layers of different materials. For example, as shown best inFIGS. 2-3, the acoustic treatment members 24 include layers 26 and 28 ofdifferent materials having different thicknesses.

The acoustic treatment members 24 can be adhered to one or both of theinner surfaces of the first panel 12 or the second panel 14. In otherwords, the acoustic treatment members 24 can fill the entire cavity 22or space between the panel portion 18 and the first panel 12 or, a space30 can be defined between the acoustic treatment member 24 and the firstpanel 12 or the second panel 14. As shown in FIG. 3, in a preferredembodiment, the second panel 14 includes a plurality of raised portions32 defined therein. The raised portions 32 provide air pockets 34 thatfurther reduce noise propagation.

In a preferred embodiment, the panel assembly 10 also includes an outeracoustic treatment member 36 that is adhered to the outer surface 14 bof the second panel 14. The panel assembly 10 can also include adecorative panel 38 or other layers adhered to or positioned adjacentthe outer surface 12 b of the first panel member 12.

FIGS. 5-6 show a plurality of panel assemblies 10 installed within thewall 100 of an aircraft fuselage. The wall 100 includes frame members102. As shown in FIG. 5, in a preferred embodiment, some of the framemembers 102 are received in some of the outer rib cavities 22. FIG. 6shows how the rib members 16 abut the window of an aircraft.

As shown in FIG. 5, in an embodiment of the invention, some of thecavities 22 can define ducting space 40 and can be used to routesystems, wire harnesses, air ducting, etc. The ducting space 40 can becoincident with space 30 in cavities 22 that include acoustic treatmentmembers 24 therein or the ducting space 40 can be defined in cavities 22that do not include any acoustic treatment members 24 therein, as shownin FIG. 5. The ducting space 40 can be used to reduce the use oftraditional ducting within the aircraft.

Unless the context clearly requires otherwise, throughout thedescription and the claims, the words “comprise,” “comprising,” and thelike are to be construed in an inclusive sense, as opposed to anexclusive or exhaustive sense; that is to say, in the sense of“including, but not limited to.” As used herein, the terms “connected,”“coupled,” or any variant thereof, means any connection or coupling,either direct or indirect, between two or more elements; the coupling ofconnection between the elements can be physical, logical, or acombination thereof. Additionally, the words “herein,” “above,” “below,”and words of similar import, when used in this application, shall referto this application as a whole and not to any particular portions ofthis application. Where the context permits, words in the above DetailedDescription of the Preferred Embodiments using the singular or pluralnumber may also include the plural or singular number respectively. Theword “or” in reference to a list of two or more items, covers all of thefollowing interpretations of the word: any of the items in the list, allof the items in the list, and any combination of the items in the list.

The above-detailed description of embodiments of the disclosure is notintended to be exhaustive or to limit the teachings to the precise formdisclosed above. While specific embodiments of and examples for thedisclosure are described above for illustrative purposes, variousequivalent modifications are possible within the scope of thedisclosure, as those skilled in the relevant art will recognize. Forexample, while processes or blocks are presented in a given order,alternative embodiments may perform routines having steps, or employsystems having blocks, in a different order, and some processes orblocks may be deleted, moved, added, subdivided, combined, and/ormodified to provide alternative or subcombinations. Each of theseprocesses or blocks may be implemented in a variety of different ways.Also, while processes or blocks are at times shown as being performed inseries, these processes or blocks may instead be performed in parallel,or may be performed, at different times. Further any specific numbersnoted herein are only examples: alternative implementations may employdiffering values or ranges.

The teachings of the disclosure provided herein can be applied to othersystems, not necessarily the system described above. The elements andacts of the various embodiments described above can be combined toprovide further embodiments.

Any patents and applications and other references noted above, includingany that may be listed in accompanying filing papers, are incorporatedherein by reference in their entirety. Aspects of the disclosure can bemodified, if necessary, to employ the systems, functions, and conceptsof the various references described above to provide yet furtherembodiments of the disclosure.

These and other changes can be made to the disclosure in light of theabove Detailed Description of the Preferred Embodiments. While the abovedescription describes certain embodiments of the disclosure, anddescribes the best mode contemplated, no matter how detailed the aboveappears in text, the teachings can be practiced in many ways. Details ofthe system may vary considerably in its implementation details, whilestill being encompassed by the subject matter disclosed herein. As notedabove, particular terminology used when describing certain features oraspects of the disclosure should not be taken to imply that theterminology is being redefined herein to be restricted to any specificcharacteristics, features or aspects of the disclosure with which thatterminology is associated. In general, the terms used in the followingclaims should not be construed to limit the disclosures to the specificembodiments disclosed in the specification unless the above DetailedDescription of the Preferred Embodiments section explicitly defines suchterms. Accordingly, the actual scope of the disclosure encompasses notonly the disclosed embodiments, but also all equivalent ways ofpracticing or implementing the disclosure under the claims.

Accordingly, although exemplary embodiments of the invention have beenshown and described, it is to be understood that all the terms usedherein are descriptive rather than limiting, and that many changes,modifications, and substitutions may be made by one having ordinaryskill in the art without departing from the spirit and scope of theinvention.

What is claimed is:
 1. A panel assembly comprising: a first panel havingan inner surface and an outer surface, and a second panel having aninner surface and an outer surface, wherein the second panel includes aplurality of rib members formed therein that extend inwardly, whereinthe rib members include an inner surface and an outer surface, wherein aplurality of panel portions are defined between the plurality of ribmembers, wherein the panel portions include an inner surface and anouter surface, wherein the inner surface of the rib members are securedto the inner surface of the first panel, and wherein the inner surfaceof the panel portions is spaced apart from the inner surface of thefirst panel to define at least first and second cavities.
 2. The panelassembly of claim 1 further comprising a first acoustic treatment memberpositioned in the first cavity.
 3. The panel assembly of claim 2 whereinthe first acoustic treatment member is adhered to at least one of theinner surface of the first panel or the inner surface of the secondpanel.
 4. The panel assembly of claim 3 wherein a space is definedbetween the first acoustic treatment member and one of the inner surfaceof the first panel or the inner surface of the second panel.
 5. Thepanel assembly of claim 4 wherein the first acoustic treatment member iscomprised of at least first and second layers.
 6. The panel assembly ofclaim 3 wherein the first acoustic treatment member is adhered to theinner surface of the second panel, and wherein the second panel includesa plurality of raised portions defined therein.
 7. The panel assembly ofclaim 3 further comprising a second acoustic treatment member, whereinthe first acoustic treatment member is adhered to the inner surface ofthe first panel and the second acoustic treatment member is adhered tothe inner surface of the outer panel, and wherein a space is definedbetween the first and second acoustic treatment members.
 8. The panelassembly of claim 2 wherein the second cavity defines a ducting space.9. The panel assembly of claim 8 wherein the second cavity does notinclude an acoustic treatment member therein.
 10. The panel assembly ofclaim 5 further comprising an outer acoustic treatment member adhered toat least a portion of the outer surface of the second panel.
 11. Thepanel assembly of claim 10 further comprising a decorative panel adheredto the outer surface of the first panel member.
 12. An aircraft fuselagewall comprising: a plurality of frame members, a panel assembly thatincludes a first panel having an inner surface and an outer surface, anda second panel having an inner surface and an outer surface, wherein thesecond panel includes a plurality of rib members formed therein thatextend inwardly and each define an outer rib cavity, wherein the ribmembers include an inner surface and an outer surface, wherein aplurality of panel portions are defined between the plurality of ribmembers, wherein the panel portions include an inner surface and anouter surface, wherein the inner surface of the rib members are securedto the inner surface of the first panel, and wherein the inner surfaceof the panel portions is spaced apart from the inner surface of thefirst panel to define at least first and second cavities, wherein atleast some of the frame members are received in at least some of theouter rib cavities.
 13. The aircraft fuselage wall of claim 12 furthercomprising a first acoustic treatment member positioned in the firstcavity.
 14. The aircraft fuselage wall of claim 13 wherein the firstacoustic treatment member is adhered to at least one of the innersurface of the first panel or the inner surface of the second panel. 15.The aircraft fuselage wall of claim 14 wherein a space is definedbetween the first acoustic treatment member and one of the inner surfaceof the first panel or the inner surface of the second panel.
 16. Theaircraft fuselage wall of claim 15 wherein the first acoustic treatmentmember is comprised of at least first and second layers.
 17. Theaircraft fuselage wall of claim 14 wherein the first acoustic treatmentmember is adhered to the inner surface of the second panel, and whereinthe second panel includes a plurality of raised portions definedtherein.
 18. The aircraft fuselage wall of claim 13 wherein the secondcavity defines a ducting space.
 19. The panel assembly of claim 18wherein the second cavity does not include an acoustic treatment membertherein.